Paperboard gable top carrier with gussets

ABSTRACT

A wrap-around carrier for carrying gable topped cartons with at least one end flap is formed without the use of adhesive by the addition of a gusset that holds the end flap securely in place. The gusset is held in place by the gable topped cartons that are contained within the wrap-around carrier. The wrap-around carrier also includes a paperboard locking mechanism that interconnects the bottom panel portions of the carrier together.

FIELD OF THE INVENTION

[0001] The present invention relates to a wrap-around paperboardcarrier, made from a unitary paperboard blank, for carrying amultiplicity of gable topped cartons.

BACKGROUND OF THE INVENTION

[0002] Gable topped cartons are well known and commonly used for holdingmany types of beverages and liquids, and may include a small drinkingstraw or other items such as a favor temporarily attached to one side ofthe carton for use by a consumer. Such cartons are sized for individualor family portions and are therefore available in several differentsizes.

[0003] For ease of shipping and handling, multiple individual portionsized gable topped cartons are typically packaged together inwrap-around paperboard carriers. For example, a linear series of threesuch gable topped cartons may be secured in the wrap-around carriershown in commonly owned U.S. Pat. No. 5,060,804, the disclosure of whichis incorporated herein by reference. The '804 patent discloses a carriermade from a unitary paperboard blank having a top panel portion, two topcorner panel portions, two side wall portions, a bottom panel portionand end flaps that cover a portion of each end of the wrap-aroundcarrier to protect against loss or pilferage of cartons or items adheredthereto.

[0004] When manufacturing this type of wrap-around carrier, an adhesiveor glue is used to secure the end flap in place. An adhesive or glue isalso used to adhere the bottom panels of the wrap-around carriertogether. Utilization of an adhesive in the manufacturing process,however, introduces a mechanical operation into the packaging line thatcan create problems. For example, gluing a carton in a wet or humidenvironment, such as a juice production and packing plant, can result ina sub-par adhesive seal, which increases the danger of malfunction.Further, not only do adhesives create additional variables in themanufacturing process, they can increase expenses by requiringadditional inventory and machinery.

[0005] It is therefore desirable to provide an economical one-piecepaperboard blank for forming a wrap-around carrier including end flapsfor protection against the loss and pilferage of items, that increasesmanufacturing ease and carrier consistency, and reduces manufacturingcosts by eliminating the need for adhesives and glues.

[0006] Accordingly, it is a broad object of this invention toincorporate the above described desirable features in a unitary blankand a carrier formed from such blank with an economy of material whichcan be processed in standard packaging equipment and processes.

SUMMARY OF THE INVENTION

[0007] The invention provides a one-piece paperboard blank for forming awrap-around carrier with end flaps that does not require any adhesivesfor the purpose of packaging a linear series of gable topped cartons.This is achieved by providing a unitary blank comprising a top panelportion, top corner panel portions, first and second side wall panelportions, first and second bottom panel portions, at least one end flapattached to one of the side wall panel portions, at least one gussetthat is attached to the end flap and one of the bottom panel portions,and means for interlocking both bottom panel portions together withoutthe addition of glues or adhesives.

[0008] When the blank is erected to form the wrap-around carrier, thegusset folds over itself and the bottom panel portion creating a 3-plyarrangement. A gable topped carton is inserted into the carrier and theweight of the carton holds down the gusset, which in turn holds the endflap in a closed position.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 is a perspective view showing an erected wrap-aroundcarrier.

[0010]FIG. 2 is a plan view of a unitary blank used to form the carriershown in FIG. 1. FIG. 3 is an enlarged fragmentary plan view of alocking tab and insert on the bottom panel portions of the blank shownin FIG. 2.

[0011]FIG. 4 is an enlarged fragmentary plan view showing a locking tabas it advances through an insert.

[0012]FIG. 5 is an enlarged fragmentary perspective view showing therelationship of a locking tab and an insert when they are fastenedtogether.

[0013]FIG. 6 is a cross-sectional view of FIG. 5, taken along line 6-6,showing the relationship of the locking tab and the insert when they arefastened together.

[0014]FIG. 7. is an enlarged plan view of a gusset of the blank shown inFIG. 2.

[0015]FIG. 8 is an enlarged perspective view of the gusset in apartially erected wrap-around carrier.

[0016]FIG. 9 is an enlarged perspective view of the gusset in a fullyerected wrap-around carrier.

DETAILED DESCRIPTION OF THE DRAWINGS

[0017] The present invention is directed to a carrier for individualsize gable topped cartons, but the principals of the invention may alsobe applied to a carrier for larger gable topped cartons or evennon-gable topped types of cartons or containers.

[0018] Referring to the figures, FIG. 1 represents one embodiment of thewrap-around carrier 92 in its erected and folded form. The carrier has atop panel portion 10, top corner panel portions 12 a and 12 b on opposedlongitudinal edges of the top panel portion, and side wall panelportions 14 a and 14 b on opposed longitudinal edges of the top cornerpanel portions. The top panel portion 10 has score lines along itsfoldable edges providing an easily removable tear strip for access tothe interior of the carrier. The top panel portion may also have graphicindicia imprinted on one of its surfaces.

[0019] The top corner panel portions extend along the top panelportion's longitudinal edges and may have oppositely disposed openings22 to securely receive portions of the gable top 24 of contained cartons26. End flaps 32 and 34 provide a protective covering for the gabletopped cartons 26, and for any attachments the cartons may have.

[0020] The unitary paperboard blank of the preferred embodiment is laidflat in FIG. 2. The paperboard blank is preferably made of Milk CartStock Grade 8341 (International Paper, Tuxedo, New York), but can bemade of any material known that is suitable to wrap-around carriers. Forexample, if one were to package larger size cartons, a thicker grade maybe advisable. First bottom panel portion 16, comprising an upper end 58,a bottom end 60, an interior end 62 and a terminal end 64, foldablyconnects to side panel portion 14 a along its interior end. Secondbottom panel portion 18 comprising an upper end 50, bottom end 52,interior end 54 and terminal end 56, foldably connects to side wallportion 14 b along its interior end. In preferred embodiments, bothbottom panel portions are of similar size. Alternate embodiments canshorten the width of one of the bottom panel portions as long as theother bottom panel potion's width is increased to make up thedifference.

[0021] A first end flap 32 is foldably attached to an end 48 a of theside wall 14 a. A second end flap 34 attached to an end 48 b of the sidepanel portion 14 b. Gusset 36 bridges end flap 32 and first bottom panelportion 16. Gusset 38 bridges end flap 34 and second bottom panelportion 18.

[0022] Connected to the second bottom panel potions along its terminalend 56 is a multiplicity of locking tabs 42, best seen in FIG. 3. Thefirst bottom panel portion contains a multiplicity of inserts 44 forreceiving the locking tabs. Cut into terminal end 64 are a multiplicityof curved notches, 46, as best seen in FIG. 3. The exact layout of theselocking tabs and inserts can vary greatly.

[0023] In alternative embodiments, the top panel contains a multiplicityof finger holes 40, spaced to optimize the comfort level of the consumerwhen carrying the wrap-around carrier.

[0024]FIG. 7 depicts one embodiment of a gusset that keeps the end flapin a closed position without the need for adhesives. The gusset 38connects the end flap 34 with bottom portion 18 and has a cut-outsection 124, forming a generally L-shaped thick bridge. In thisembodiment, the outer side edges of the L-shaped thick bridge 116 and118 connect at corner 126 at an angle greater than 90°, while the innerside edges 120 and 122 connect at corner 128 at an angle less than 90°.However, the angles of corners 126 and 128 can each be greater or lessthan 90°, in any combination, while maintaining the advantages andspirit of the invention.

[0025] A fold line 98 further divides the gusset into two trapezoidalsections 94 and 96. The fold line 98 runs the length of the L-axis ofthe gusset. A fold line 112 runs the length of the bottom end oftrapezoidal section 96, overlapping upper end 50. A fold line 130 runsthe length of an end of trapezoidal section 94, overlapping a side ofend flap 34.

[0026]FIG. 8 shows the gusset folding from the unitary paperboard blankdepicted in FIG. 2 to the fully erected wrap-around carrier depicted inFIG. 1. As indicated by arrow A, the gusset folds upward, out the planeof the blank, along fold line 98. As that happens, end flap 34 begins tobe pulled toward bottom panel portion 18 as indicated by arrows B and C.

[0027]FIG. 9 shows the position of the gusset when the carrier is fullyerected. Here the two trapezoidal sections of the gusset, 94 and 96,touch each other in a 2-ply face to face gusset arrangement 110. This2-ply face to face gusset arrangement is fully folded over fold line112, so that the gusset arrangement 110 lies on top of the bottom panelportion 18 in a face-to-face manner. Thus, the bottom panel portion andthe gusset arrangement create a 3-ply paperboard arrangement 114,located on the bottom side of the wrap-around carrier. The 3-plyarrangement is held in place without any adhesives by gable toppedcarton 26, which is carried within the wrap-around carrier. The gusset,held down by gable topped carton 26, in turn holds end flap 34 in aclosed position at the end of the carrier.

[0028] Many types of locking mechanisms are known in the prior art andmay be used to secure the bottom panels together without adhesives,including but not limited to, those described in U.S. Pat. Nos.3,432,029, 4,709,284, 5,180,100, 5,3311,994, 5,437,363, 5,704,542,5,855,318, 5,941,453. One embodiment involves locking tab 42 and insert44, as seen in FIG. 3. The locking tab contains a primary tab 66, a basetab 82, and a secondary tab 68. The base tab 82 and secondary tab 68 arefoldably connected along longitudal fold line 70. The primary tab isgenerally semi-circular in shape, with end prongs 72 and 74 that lay ina linear plane parallel to fold line 70. The end prongs extend past thebase tab 82, creating a locking shoulder 84. The base tab is generallytrapezoidal in shape, with side edges 80 that diverge from one anotheras they extend away from the primary tab. The base tab connects to theprimary tab on the same linear plane as the bottom of the end prongs,with end points that curve inward in a generally circular configuration.

[0029] Secondary tab 68 is generally trapezoidal in shape, with a topside that corresponds to fold line 70, side edges 80 that diverge fromone another as they extend away fold line 70 and continue the linearpath of the base tab's edges 80. The bottom side consists of fold lines86 that flank arcuate slit 88. When locking tab 42 is bent along foldlines 86, a secondary locking tab 90 is formed in the shape of an arcedprotrusion that corresponds to the shape of arcuate slit 88.

[0030] Insert 44 is generally rectangular in shape with top edge 100,bottom edge 102, and slide track edges 104. The top edge is a straightline parallel to the second bottom panel portion's terminal end. Slidetrack edges 104 have an outwardly curved shape that curves inward at thepoint where the insert's slide track edges meet the insert's top edge,creating corner notches 106. Small cut lines 108 flank the bottom edge,which is parallel to the top edge. The cut lines 108 take on ahalf-teardrop shape, with the bulge of the half-teardrop facing awayfrom the terminal end.

[0031] FIGS. 4-6 show how the locking tabs interconnect. The primary tab66 is inserted through the insert's bottom edge 102, as shown in FIG. 4.Entry of the primary tab 66 is aided by the cut lines 108 the flank theinsert's bottom edge 102. The primary tab 66, pointing upwardsperpendicularly out of the insert 44, is then moved in a plane parallelto the insert toward the insert's top edge 100. This movement isfacilitated by the slide tracks 104 that curve outward and reducefriction. When the primary tab is by the top edge 100, the secondary tab90 is pushed upwards though the insert's bottom edge 102, so that thelocking tab is in a plane parallel to the insert. The secondary tab 90then fastens over the insert's bottom edge 102, while the primary tab 66locks over the insert's top edge 100, aided by friction caused by thelocking shoulder 84, as shown in FIG. 6. A cross-sectional view of theinterconnected tab and insert is shown in FIG. 5.

[0032] Although the invention has been described with reference to apreferred embodiment, it will be appreciated by one of ordinary skill inthe art that numerous modifications are possible in light of the abovedisclosure. For example, the exact shape of the gusset can vary byaltering the width and angles of L-shaped bridge while still achievingthe same results. Further, only one gusset and end flap may be usedinstead of two, or gussets and end flaps may be used on both ends of thecarrier. Additionally, the type of paper stock and variables such asthickness and weight of the stock may be modified to accommodate othercarton types and sizes. All such variation and modifications areintended to be within the scope and spirit of the invention.

What is claimed is:
 1. A one piece paperboard blank for a wrap-aroundcarrier to package a linear series of cartons, said blank comprising:(a) a top panel portion, (b) top corner panel portions foldably attachedto opposing longitudinal edges of the top panel portion, (c) first andsecond side wall panel portions foldably attached to the top cornerpanel portions, (d) a first bottom panel portion foldably attached tosaid first side wall panel portion, (e) a second bottom panel portionfoldably attached to said second side wall portion, (f) an end flapfoldably attached to one of said side wall panel portion, (g) a gussetfoldably attached to said end flap and at least one of said first orsecond bottom panel portion, and (h) means for interlocking said firstbottom panel portion and said second bottom panel portion togetherwithout the addition of glues or adhesives.
 2. The blank as set forth inclaim 1, wherein the interlocking means comprises a multiplicity oflocking tabs foldably attached to said first bottom panel portion, and amultiplicity of inserts cutout of said second bottom panel portion,wherein said locking tabs fasten and interconnect with said inserts. 3.The blank as set forth in claim 1, wherein said gusset comprises agenerally L-shaped connection between said end flap and one of saidbottom panel portions.
 4. The blank as set forth in claim 3, wherein thegenerally L-shaped connection comprises outer edges that connect at anangle greater than 90°, and inner edges that connect at an angle lessthan 90°.
 5. The blank as set forth in claim 3, wherein said gussetfurther comprises two trapezoidal sections, wherein said trapezoidalsections are foldably connected to one another by a fold line that runsthe length of the axis of said L-shaped connection.
 6. The blank as setforth in claim 1, further comprising at least one internal compressioncut-out along the fold line between said first bottom panel portion andsaid first side wall panel portion, and diametrically opposed from atleast one internal compression cut-out along the fold line between saidsecond bottom panel portion and said second side wall panel portion. 7.The blank as set forth in claim 1, wherein said top panel portion hasscore lines along its foldable edges thereby providing an easilyremovable tear strip for access to the interior of said carrier.
 8. Theblank as set forth in claim 1, wherein said top corner panel portionsfurther comprises oppositely disposed openings to receive portions of atop of a gable topped carton.
 9. The blank as set forth in claim 1,wherein said top panel further comprises a multiplicity of generallycircular cutouts remote from the sides of said top panel.
 10. Awrap-around carrier formed from a unitary bland of paperboard folded andinterconnected into a tube-like structure, comprising: (a) a firstbottom panel portion and a second bottom panel portion, said firstbottom panel portions interconnected to said second bottom panelportion, (b) a first upstanding side wall portion foldably connected tosaid first bottom portion, and a second upstanding side wall portionfoldably connected to said second bottom portion, (c) corner panelportions foldably connected to said first and second side wall portions,(d) a top panel portion foldably connected between the corner panelportions, (e) at least one end flap foldably attached to one of saidside wall portions that partially covers one end of the tube-likestructure (f) at least one gusset foldably attached to said end flap andone of said bottom panel portions, whereby the gusset is held still bythe cartons positioned within the wrap-around carrier, holding the endflap in position.
 11. The carrier as set forth in claim 10, wherein saidfirst and second bottom panels are interconnected by a multiplicity oflocking tabs foldably attached to said first bottom panel portion, witha multiplicity of inserts cutout of said second panel portion.
 12. Thecarrier as set forth in claim 10, wherein said gusset comprises agenerally L-shape connection between the said end flap and said bottompanel.
 13. The carrier as set forth in claim 12, wherein said gussetfurther comprises two trapezoidal sections, said trapezoidal sectionsconnected to one another by a fold line along the axis of the L-shapedgusset, wherein said trapezoidal sections are folded together in a faceto face arrangement.
 14. The carrier as set forth in claim 13, whereinsaid face to face arrangement is folded over said bottom panel portionand held in place by a gable topped carton that is loaded into saidcarrier.
 15. The carrier as set forth in claim 10, further comprising atleast one internal compression cut-out along the crease between saidfirst bottom panel portion and a said first side wall, and diaposed fromat least one internal compression cut-out along the crease between saidsecond bottom panel portion and said second side wall.
 16. The carrieras set forth in claim 10, wherein said top panel portion has score linesalong its foldable edges, thereby providing an easily removable tearstrip for access to the interior of said carrier.
 17. The carrier as setforth in claim 10, wherein said corner panel portions further comprisesoppositely disposed openings that receive top opening tabs of aplurality of cartons positioned in a row within said carrier.
 18. Thecarrier as set forth in claim 10, wherein said top panel furthercomprises a multiplicity of generally circular cutouts remote from thesides of said top panel portion.
 19. A one piece paperboard blank for awrap-around carrier to package a linear series of cartons, said blankcomprising: (a) a top panel portion, (b) top corner panel portionsfoldably attached to opposing longitudinal edges of the top panelportion, (c) first and second side wall panel portions foldably attachedto the top corner panel portions, (d) a first bottom panel portionfoldably attached to said first side wall panel portion, (e) a secondbottom panel portion foldably attached to said second side wall portion,(f) an end flap foldably attached to one of said side wall panelportion, (g) a gusset foldably attached to said end flap and at leastone said bottom panel portion, and (h) a multiplicity of locking tabsfoldably attached to said first bottom panel portion, and a multiplicityof inserts cutout of said second bottom panel portion.
 20. The blank asset forth in claim 19, wherein said gusset comprises a generallyL-shaped connection between said end flap and one of said bottom panelportions.
 21. The blank as set forth in claim 20, wherein the generallyL-shaped connection comprises outer edges that connect at an anglegreater than 90°, and inner edges that connect at an angle less than90°.
 22. The blank as set forth in claim 19, wherein said top cornerpanel portions further comprises oppositely disposed openings to receiveportions of a top of a gable topped carton.